An implementable strategy combining QFD, DOE and SPC for optimization and variation reduction in quality
Date
1996
Authors
Swaminathan, R.
Major Professor
Advisor
Berger, Roger W.
Committee Member
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Abstract
The approach presented involves combining several TQM tools in achieving efficiency and quality. Quality Function Deployment which helps maintain focus on customer requirements in combination with Experimental design and Statistical Process Control have been used. Little research has been on applying a combination of these tools and techniques to a manufacturing environment. An additional objective of this research is to apply this strategy to small businesses and to prove its effectiveness. A diesel engine thermostat manufacturing facility was used as the focus of this research. Quality Systems 9000 for used as the backbone for driving this quality improvement cycle. QFD , FMEA, DOE and SPC studies were conducted at this facility and results have been analyzed in later sections to provide an insight to the effectiveness of the combined methodology. It is a truly integrated approach that it uses the output from the QFD study to drive the Design of experiments and using SPC to keep the process under control. All these is done with the core concepts of business in mind—Set the vision, Prioritize and implement, improve critical process, apply analytical techniques and finally automate the process. These analytical tools act as bridge between streamlining to critical product and process features and the business processes.
This study was conducted at an engine thermostat manufacturing facility. Though the company was into statistical process control, it was felt that better rewards can be reaped by systematically identifying the customers needs and wants using QFD and analyzing the process using Failure Mode and Effect Analysis (FMEA) and translating these requirements into product and process characteristics using DOE. SPC could then be performed as the final step in an effort to optimize and reduce variation.
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thesis